dsi-dywidag prestressing systems using bars emea
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ETA Approvals ...........................................................................................................4
System description .................................................................................................... 5
Prestressing Bars / Technical Data ............................................................................6
System overview ........................................................................................................7
Overview of anchorages ............................................................................................8
Applications ...............................................................................................................9
Overview of bonded bar tendons .............................................................................10
Overview of unbonded and external bar tendons .....................................................11
Geometrical characteristics of accessories ............................................................. 12
Installation ...............................................................................................................13
Stressing and grouting ............................................................................................. 14
Equipment for stressing and grouting ......................................................................15
Contents
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Construction products with an Euro-pean Technical Approval (ETA) meetall essential demands given in theConstruction Products Directive (CPDThe ETA holder is authorized to applyCE-marking (Conformit Europennon his product. The CE-marking certi-es the conformity with the technicalspecication and is the basis for thefree movement of goods within the EUmember states. DSI is proud to haveEuropean Technical Approvals for itsPT-systems with bars, bonded strandsand unbonded strands.
ETA Approvals
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DYWIDAG Prestressing Systemsare world renowned for reliability andperformance, most suitable for allapplications in post-tensioned andprestressed constructions. Theyembrace the whole spectrum from bridgeconstruction, buildings, to civilapplications, above and underground.
The rst ever structure built with a pro-totype DYWIDAG Post-TensioningSystem using bars was the arch-bridge
Alsleben (Germany) in 1927. From thattime on DYWIDAG has continuouslyimproved its systems to keep up with thegrowing demand of modern constructiontechnology. In addition to the traditionalpost-tensioning system using bars, thatis mainly geared towards geotechnicalapplications, building rehabilitation andstrengthening, DSI offers a completeproduct line in strand prestressing (bon-ded, unbonded and external) as well asstay-cables being able to fully serve thepost-tensioning construction. DYWIDAGPrestressing Systems have always com-bined highest safety and reliability stan-dards with most economical efciency intheir research and development. Depen-dable corrosion protection methods of theDYWIDAG Prestressing Systems contri-bute to the longevity of modern construc-tion. High fatigue resistance is achievedwith optimized material selection andcautious detailing of all the componentsespecially in their system assembly.
The post-tensioning system for theprestressing of structures with bars (inter-nal bonded, unbonded and external ten-dons) is regulated in European Technical
Approval ETA-05/0123. This ETA can bedownloaded at: http://www.dywidag-systems.com/emea/downloads/dsi-approvals/european-approvals.html
System Description
Ground anchors of up to 47 mm areprovided for geotechnical applications.
Additionally, DSI USA providesDYWIDAG Prestressing Systems with65 and 75 mm threadbars.
Internal bar tendons are mainly used inconcrete, composite and masonrystructures. Internal unbonded andexternal bar tendons are used for con-crete, composite, steel, timber andmasonry structures. Typical applicationsare transversal prestressing, strengthe-ning of bridges, rehabilitations, connec-tion elements for steel structures andmachines and temporary applications.
Uhlavu Bridge, Pilsen, Czech Republic
Typical Coupling, Uhlavu Bridge, Pilsen, Czech Republic
Advantages and Characteristics
n Easy system handlingn Robust designn Flexible transport length due to couplersn Also applicable for (very) short tendons due to little slipn Used in new structures and for strengthening of existing structuresn Suitable as longitudinal or transversal tendonsn Usable as shear reinforcement
n Usable as straight or curved tendonsn Can be used as hangers for concrete or steel arch bridgesn Usable for the temporary or permanent connection of precast
concrete elementsn Many combination of any structural material are possible
(such as steel with concrete)n Preassembled unbonded or external tendons with permanent corrosion
protection are available
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Prestressing Bars and Technical Data
GeneralThe prestressing bars are hot-rolled, tem-pered from the rolling heat, stretched andannealed, with a circular cross section.
The bars are of prestressing steelY 1050 H according to prEN 10138-4.
The threadbars and plain bars areavailable in mill length up 18 m andmay be cut to specied lengths beforeshipment to the jobsite.
Threadbars
Threadbars are available in diameters17.5, 26.5, 32, 36, 40 and 47 mm.
The threadbars feature continuoushot-rolled ribs providing a right-handedthread along the entire length.
The threadbar can be cut anywhere andis threadable without further preparation.
The threadbars are specied bynominal diameter and WR, e.g. 26 WR
Plain bars
Plain bars are available in diameters32 and 36 mm.
Both ends of a plain bar cut to the lengthspecied in the project are provided withspecial cold-rolled threads.
The thread lengths are manufactured inthe shop according to the specicationsof the project.
The plain bars are specied bynominal diameter and WS, e.g. 32 WS.
THREADBAR Plain bar
Designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS
Nominal diameter d s [mm] 17.5 26.5 32 36 40 47 32 36
Cross section area S n [mm] 241 552 804 1,018 1,257 1,735 804 1,018
Nominal mass per metre 1 M [kg/m] 1.96 4.48 6.53 8.27 10.20 14.10 6.31 7.99
Pitch c [mm] 8 13 16 18 20 21 3 3
Characteristic breakingload Fm [kN] 255 580 845 1,070 1,320 1,820 845 1,070
Max. initial stressing force 2P m0,max = S n x 0,8 x f p,k [kN] 204 464 676 856 1,056 1,457 676 856
Max. overstressing force 3 P 0,max = S n x 0,95 x f p0,1k
[kN] 219 499 722 912 1,131 1,566 722 912
1The nominal mass per metre includes 3.5% not load bearing portion of ribs. 2The given values are maximum values according to Eurocode 2, i.e. min (k1xfpk, k2x fp0.1k ) applies. The fulllment of the stabilization criteria and the requiremencracks width in the load transfer tests were veried at 0.8 x Fpk.
Fpk = Sn x fpk Fp0.1k = Sn x fp0.1k 3Overstressing is permitted if the force in the prestressing jack can be measured to an accurary of 5% of the nal value of the prestressing force.
Technical data
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Available tendons Anchor
plate 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS
Bonded bar tendonwith QR-plate anchoragewith additional reinforcement
2074
Bonded bar tendonwith small solid rectangular plate anchoragewith additional reinforcement
2076
Bonded bar tendonwith QR-plate anchoragewithout additional reinforcement
2074
Bonded bar tendonwith small solid rectangular plate anchoragewithout additional reinforcement
2076
Bonded bar tendonwith small solid square plate anchoragewithout additional reinforcement
2011
Bonded bar tendonwith solid rectangular plate anchoragewith additional reinforcement
2012
Unbonded and external bar tendonwith solid square plate anchoragewithout additional reinforcement
2011
Unbonded and external bar tendonwith solid rectangular plate anchoragewith additional reinforcement
2012
System Overview
4 Hex nuts 2002 are not included in ETA-05/0123.
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Stressing anchorage, bondedThe bar is xed with the domed
anchor nut and the retaining nut to theanchorage plate and this latter will bexed to the scaffolding. The retaining
nut provides the connection to the duct.Grouting is performed through the grout
cap, the domed anchor nut with the threegrout slots and the retaining nut.
Fixed anchorage, bondedThe xed anchorage is mostlycompletely embedded in the con-crete. The domed anchor nut is tackwelded perpendicularly onto the anchorplate. The duct sleeve B ends direct-ly at the anchor plate the duct will beinjected respectively vented there. Axed anchorage can be designed as astressing anchorage; the requiredbar-over length for the stressing can bedispensed.
Stressing anchorage, unbonded Against water intrusion in the
anchorage region a connection tube iswelded to the anchor plate for bridging of
a gap behind the anchor plate.Different corrosion protection systems
are available.
Fixed anchorage, unbondedThe xed anchorage is mostlycompletely embedded in the concrete.The domed anchor nut is tack weldedperpendicularly onto the anchor plate.The prestressing bar will be providedwith the respective corrosion protection.The xed anchorage can be carried outas an unbonded stressing anchorage,too.
domed anchor nutprestressing bar WR/W
hex nuttoroidal ring
grout cap sealing ring anchor plate
retaining nut
anchor plate
anchor plate with connection tube
domed anchor nut
duct sleeve B
prestressing bar WR/WS
domed anchor nuttube
heatshrinking sleeveprestressing bar WR/WS
domed anchor nut
anchor plate
prestressing bar WR/WS
tube heatshrinking sleeve
Overview of Anchorages
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Prestressing bar tendons can be usedat new structures and for strengtheningof existing structures, as longitudinalor transversal tendons, as shearreinforcement, straight or curved,as hangers at concrete or steel archbridges, for temporary or permanent
connections of precast concreteelements, xations of concrete toconcrete, new concrete to old concrete,steel to concrete, concrete to masonryor any combination of members made ofany structural material.
Applications
Grand-Mre Generating Station, Canada
Church of Our Lady, Germany
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Bonded bar tendons are embedded inconcrete. The corrosion protection of theprestressing steel and the bond with thestructural concrete is provided by groutinjected in the ducts.
A bonded tendon is intendedto be used for concrete, compositeand masonry structures.
Overview Bonded Bar Tendons
Bonded bar tendon, design QR-plate,square and rectangular solid plates
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Overview Unbonded and External Bar Tendons
Unbonded and external bar tendonsare installed either inside or outsidethe cross section of the structure. Forcorrosion protection various systemsare available, all of which do not bondwith the structure. The tendons may be
restressed at any time and dependingon the tendon type, they can also beremoved or exchanged.
Internal unbonded and external tendonsare intended to be used for concrete,
composite, steel, timber and masonrystructures.
The corrosions protection of unbondedand external tendons depends on anenvironmental conditions and service time.
Bar tendons with free tendon duct,permanent corrosion protection executedduring grouting before stressing,design square and rectangular solid plates
Bar tendons with free tendon duct,permanent corrosion protection executedby heatshrinking sleeve, design square andrectangular solid plate
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Tendon with free tendon duct Tendon without free tendon duct
Corrosionprotection for
Temporarycorrosionprotection 3 years
Permanent corrosion protection Permanent corrosion protection
ThreadbarPlain bar coating
grouting withcement grout
before stressing(installation)
grouting withcement grout after
stressing
heatshrinkingsleeve or corrosion
protection tape
corrosionprotectioncompound
heatshrinking sleeveor corrosion
protection tape
corrosioprotectiocompoun
coating acc. toEN ISO 12944-5with protection
tube (PE)
cement grout withprotection tube
(PE or steel)
cement grout withprotection tube
(PE or steel)
heatshrinkingsleeve or corrosion
protection tapewith protection
tube (PE or steel)
protection tube(PE), void groutwith corrosion
protectioncompound
heatshrinkingsleeve or corrosion
protection tapewith protection
tube (PE or steel)
corrosioprotection tawith protect
tube (PE
Anchorage,range of
connectiontube
corrosionprotection
compound ortape
sealing ringplus corrosion
protectioncompound tape
sealing ringplus grout
sealing ring orheatshrinking
sleeveplus corrosion
protectioncompound or tape
sealing ring orheatshrinking
sleeveplus corrosion
protectioncompound
sealing ring orheatshrinking
sleeveplus corrosion
protectioncompound or tape
sealing ringheatshrink
sleeveplus corrosi
protectiocompoun
Anchorage,range of
anchor nut
corrosionprotection
compound ortape
corrosionprotection
compound or tapeor grout
corrosionprotection
compound or tapeor grout
corrosionprotection
compound or tape
corrosionprotectioncompound
corrosionprotection
compound or tape
corrosioprotectiocompoun
cap, PE or steel cap, PE or steel cap, PE or steel
Coupler heatshrinkingsleeve
tubes (PE or steel) with transition pieces, sealed with heatshrinking sleeve or tape,lled with corrosion protection compound or tape or grout
tube with transition pieces, lled witcorrosion protection compound
Overview of Corrosion Protection Systems
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Geometrical Characteristics of Accessories
Overview of Tensioning Jacks for Prestressing Tendons
THREADBAR Plain bar
Bar designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS
Domed Anchor Nut 2099length [mm] 55 75 90 100 115 135 46 60
width across at [mm] 36 50 60 65 70 80 55 65
Hex nut 4 2002length [mm] 60 80 90 110 120 140 55 80
width across at [mm] 41 46 55 60 70 80 55 60
Coupler (Standard) 3003length [mm] 100 170 200 210 245 270 110 160
outside diameter [mm] 36 50 60 68 70 83 60 68
Square Solid Plate 2011
width [mm] 110 150 180 200 220 260 180 200
length [mm] 110 150 180 200 220 260 180 200
thickness [mm] 25 35 40 45 45 50 40 45
Rectangular Solid Plate(Unbonded and Bonded) 2012
width [mm] 100 130 140 150 160 200 140 150
length [mm] 130 150 180 220 250 280 180 220
thickness [mm] 30 35 40 50 60 60 40 50
Rectangular Solid Plate(Bonded) 2076
width [mm] 80 120 140 160 180 210 140 160
length [mm] 90 130 165 180 195 235 165 180
thickness [mm] 25 30 35 40 45 55 35 40
QR-Plate 2074
width [mm] - 120 140 160 180 - - 160
length [mm] - 130 165 180 195 - - 180
thickness [mm] - 30 35 40 45 - - 40
Corrugated Duct 4061internal diameter [mm] 25 38 44 51 55 65 44 51
outside diameter [mm] 30 43 49 56 60 70 49 56
Minimum Bar Protrusion at stressing anchorage [mm] 60 75 90 100 115 135 46 60
THREADBAR Plain bar
Bar designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS
60 Mp x x x 1 x1
110 Mp x x x x x x
200 Mp x1 stressing force limited to 625 kN max.
4 Hex nuts 2002 are not included in ETA-05/0123.
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ValueFormwork
Grout Tube
Pocket Former
Duct Duct Sleeve A Duct
Anchor PlateHex Nut
Stressing End
Domed Anchor Nut
Retaining Nut
Installation
DYWIDAG-Systems Internationaloffers a full line of special installationaccessories to facilitate eld assemblyand installation. Installation shall becarried out by properly trainedand experienced personnel.Tendons can be delivered to the jobsiteprefabricated when desired(e.g. unbonded bar tendon), too.
In the area of anchorage adequatespace shall be accomplished througha pocket former assembled at theformwork before concreting in order tput on the jack and for the grout cap.
Jeju Port Extension, South Korea
Woodrow Wilson Bridge, Washington, D.C., USA
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Stressing and Grouting
The small, light and conveniently operatedDYWIDAG-Systems International jacksfacilitate the stressing operation. Heavylifting aids are generally not necessary.
Stressing notesStraight tendons are generally stressedfrom one end only. In order to reducefriction losses (especially in drapedtendons) it is recommended to stressfrom both sides.
The prestressing load can be adjustedup and down at any given time untilthe tendon is fully grouted by simplyreinstalling the jack. This allows partiallystressing. Several controls during andafter the stressing operation check theeffective stressing load:
n bar protrusion at the anchoragebefore and after stressing to evaluatethe effective elongation
n counter control for elongation duringstressing operation
n gauge control for hydraulic pressure
To comply with exceptional highdemands on accuracy for example onvery short tendons special accessoriescan be applied to minimize the inuenceof alignment tolerances.
GroutingThe durability of bonded post-tensionedconstruction depends to a great degreeon the success of the grouting operation.The hardened cement grout providesbond between concrete and tensileelements as well as primary long termcorrosion protection (alkaline medium)for the prestressing steel.
DYWIDAG-Systems International hasdeveloped a grouting operation thatis based on highly plasticized groutwith thixotropic properties, and utilizesdurable grouting equipment. Advancedmethods such as pressure grouting,post-grouting and vacuum grouting areall results of many years of development.
Grouting is always done from a low-pointof the tendon. This can be one of theanchorages with a grout cap with groutinlet or along the tendon utilizing anintermediate grout saddle. All groutingcomponents are threaded for easy, fastand proper connection.
The jack is pushed over a pull rod couplerthat is threaded onto the bar protrusionbehind the domed anchor nut. The jack isthen xed with a pulling nut.
The tension load is hydraulically transfer-red. The domed anchor nut is tightenedby an internal wrench. The bar 47 WR hasa specially equipped stressing jack.
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E
A B
L
D
E
L
A B
D
C
F
Equipment for Stressing and Grouting
Tensioning jacks
Dimensions (for Block-Out design)
Tensioning jacks L E stroke piston area Ak capacity max. piston weight A B C D F pressure [mm] [mm] [mm] [cm] [kN] [bar] [kg] [mm] [mm] [mm] [mm] [mm]60 Mp Series 04 401 190 50 132.5 625 50 36 225 176 3) 3) 30060 Mp Series 05 456 190 100 132.5 625 50 44 225 231 3) 3) 300
110 Mp Series 01 494 267 50 235.6 1,100 50 46 275 2194)
4)
375110 Mp Series 03 594 267 150 235.6 1,100 50 54 275 319 4) 4) 375200 Mp 865 315 150 361.3 2,000 60 172 350 515 - 270 -
C D for type of bar [mm] [mm]3) 105 106 18 WR, 26 WR, 32 WS 135 114 32 WR4) 122 106 26 WR 125 110 32 WS 125 120 32 WR, 36 WR/WS 134 134 40 WR
Hydraulic pumps
Hydraulic pumps Tensioning jacks 60 Mp 110 Mp 200 Mp77-193 A n nR 3.0 V n nR 6.4 n n n
Pump type max. operating oil ow rate usable weight dimensions pressure oil capacity with oil 1 L x W x H [bar] [l/min] [l] [kg] [mm]77-193 A 600 3.0 10 63 420x380x480R 3.0 V 600 3.0 13 98 600x390x750R 6.4 600 6.4 70 310 1,400x700x1,100
1) Hydraulic pumps will be supplied without oil.
Grouting equipment (mixing and pumping)
Grouting max. injection capacity weight dimensionsequipment pressure L x W x H [bar] [l/h] [kg] [mm]MP 2000-5 15 420 300 2,000x950x1,600
Pump Type R 6.4Pump Type 77-193 A
Mixer MP 2000-5
Tensioning jack 110 Mp/60 Mp Tensioning jack HOZ 200 Mp
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A U S T R I A A R G E N T I N A A U S T R A L I A
B E L G I U MB O S N I A A N D H E R Z E G O V I N A
B R A Z I LC A N A D A
C H I L EC O L O M B I A
C O S TA R I C A C R O AT I A
C Z E C H R E P U B L I CD E N M A R K
E G Y P TE S T O N I A F I N L A N DF R A N C E
G E R M A N YG R E E C E
G U AT E M A L A H O N D U R A S
H O N G K O N GI N D O N E S I A
I TA LYJ A PA NK O R E A
L E B A N O NL U X E M B O U R G
M A L AY S I A M E X I C O
N E T H E R L A N D SN O RWAY
O M A NPA N A M A
PA R A G U AYP E R U
P O L A N DP O RT U G A L
Q ATA RS A U D I A R A B I A
S I N G A P O R ES O U T H A F R I C A
S PA I NS W E D E N
S W I T Z E R L A N DTA I WA N
T H A I L A N DT U R K E Y
U N I T E D A R A B E M I R AT E SU N I T E D K I N G D O M
U R U G U AYU S A
V E N E Z U E L A
www.dywidag-systems.com
Please note:This brochure serves basic informationpurposes only. Technical data and informationprovided herein shall be considerednon-binding and may be subject to changewithout notice. We do not assume any liabilityfor losses or damages attributed to the useof this technical data and any improperuse of our products. Should you requirefurther information on particular products,please do not hesitate to contact us.
AustriaDYWIDAG-SystemsInternational GmbH Alfred-Wagner-Strasse 14061 Pasching/Linz, AustriaPhone +43-7229-61 04 90Fax +43-7229-61 04 980E-mail office@dywidag-systems.atwww.dywidag-systems.at
FranceDSI-ArtonRue de la CrazZ.I. des Chartinires01120 DagneuxFrancePhone +33-4-78 79 27 82Fax +33-4-78 79 01 56E-mail dsi.france@dywidag.frwww.dywidag-systems.fr
Germany DYWIDAG-SystemsInternational GmbHSchuetzenstrasse 2014641 Nauen, GermanyPhone +49 3321 44 18 0Fax +49 3321 44 18 18E-mail suspa@dywidag-systems.com
DYWIDAG-SystemsInternational GmbHMax-Planck-Ring 140764 Langenfeld, GermanyPhone +49 2173 79 02 0Fax +49 2173 79 02 20E-mail suspa@dywidag-systems.comwww.dywidag-systems.de
DYWIDAG-SystemsInternational GmbHGermanenstrasse 886343 Koenigsbrunn, GermanyPhone +49 8231 96 07 0Fax +49 8231 96 07 10E-mail geotechnik@dywidag-systems.comwww.dywidag-systems.de
DYWIDAG-SystemsInternational GmbHSiemensstrasse 885716 Unterschleissheim, GermanyPhone +49-89-30 90 50-100Fax +49-89-30 90 50-120E-mail dsihv@dywidag-systems.comwww.dywidag-systems.com
Italy DYWIT S.P.A.Viale Europa 72 Strada A 7/920090 Cusago (MI), ItalyPhone +39-02-901 65 71Fax +39-02-901 65 73 01E-mail info@dywit.itwww.dywit.it
NetherlandsDYWIDAG-SystemsInternational B.VVeilingweg 25301 KM Zaltbommel, NetherlandsPhone +31-418-57 89 22Fax +31-418-51 30 12E-mail email@dsi-nl.nlwww.dywidag-systems.com
PolandDYWIDAG-SYSTEMSINTERNATIONAL Sp. z o.o.ul. Przywidzka 4/6880-174 Gdansk, PolandPhone +48-58-300 13 53Fax +48-58-300 13 54E-mail dsi-polska@dywidag-systems.comwww.dywidag-systems.pl
PortugalDYWIDAG SISTEMASCONSTRUCTIVOS, SA Rua D. Manuel I, n.24 A Quinta da Parreirinha2695-003 Bobadela (Loures), PortugalPhone +351-21-89 22 890Fax +351-21-89 22 899E-mail dywidag@dywidag-sistemas.com
SpainDYWIDAG SISTEMASCONSTRUCTIVOS, S.A. Avd/de la Industria, 4Pol. Ind. la Cantuena28947 Fuenlabrada (Madrid), SpainPhone +34-91-642 20 72Fax +34-91-642 27 10E-mail dywidag@dywidag-sistemas.comwww.dywidag-sistemas.com
United KingdomDYWIDAG-SystemsInternational Ltd.Northeld RoadSoutham, WarwickshireCV47 0FG, Great BritainPhone +44-1926-81 39 80Fax +44-1926-81 38 17E-mail sales@dywidag.co.ukwww.dywidag.co.uk
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